Jump to content

Recommended Posts

This seems like the best place to post this as this Headlight is not make/model specific and everyone who has one hates it's mediocre light output. I like the styling of this light so I just wanted to upgrade it. The only write-up I could find was years ago (ADV-monster?) and no specifics on how it could be repeated by someone else. So here we are....

 

I pulled out the stock High Beam reflector assembly to get measurements so I'll start there:

I went to Home Depot hoping to find maybe a small plate of aluminum, kickplate etc that I could use for my adapter plate to mount my new Baja Designs Squadron R light to this assembly. I took the old glass reflector for sizing comparison. After scratching my head for a while and stumping a few well-meaning employees who attempted to help me think outside the box for about 1/2 second each I came across this steel cover for an outdoor electrical box that was the PERFECT outside diameter. That saved me a TON of time as I only needed to notch the outside in a few places and cut out the inner hole the new light fits into.

20190622_201938.jpg

20190622_202009.jpg

20190622_202044.jpg

Share this post


Link to post
Share on other sites

Marked and notched the outside of the plate to fit the housing. I lined up the existing holes with two of the notches which makes it easier to line up the center hole later.

 

20190622_202452.jpg

20190622_204824.jpg

20190622_204914.jpg

Edited by DirtyErnie
added photos

Share this post


Link to post
Share on other sites

At this point it's ready for the inner hole the BD light mounts in. Mark center of the plate, measure and use the box hole for a template for the odd shaped rounded-square. If this hole is not lined up centered and level the light will be noticeably crooked when done! Take your time to measure and mark carefully! The existing holes were handy for screwing the plate to my workbench (with fender washers) to hold it in place while drilling, cutting and filing.

 

20190622_210619.jpg

20190623_085631.jpg

Share this post


Link to post
Share on other sites

After the center hole was fine tuned with a round and half-round file the new light is test fit in the assembly. The back housing fits over the cooling fins, but I bench tested the light for about 15 minutes before starting this project and it gets very hot. So free air around the fins is important and the back cover needs to be modified.

 

20190623_101629.jpg

20190623_101752.jpg

20190623_103047.jpg

  • Like 1

Share this post


Link to post
Share on other sites

Initially the plan was to cut it wide open on my scribe marks on the back but instead I decided to use the step-bit to fill the area with large holes instead. My reason for this was the wires for my bike mostly reside behind the headlight and I don't want the wires resting or rubbing on the hot fins. I'm hoping this is enough ventilation for it, I haven't put it into use yet.

20190623_105554.jpg

Share this post


Link to post
Share on other sites

Very creative! I’d guess (completely uneducated) that you should have enough air flow.

  • Like 1

Share this post


Link to post
Share on other sites

Finishing the mounting plate, I cut the mounting bracket that came with the BD light into three pieces. I used tin snips but it was very hard to cut and ended up bending the parts I intended to use a bit. Probably easier with a jigsaw or hacksaw. Using a couple of extra flat washers to space the tab out from the light before bolting it on reduced the amount I had to bend the tabs to make them fit neatly on the sides of the light. I cleaned the paint off the areas I intended to weld the tabs on, probably should've just removed all the paint from the plate at this point. Remember if you are welding plated parts (most electrical fittings, conduit and boxes are plated) to either remove the surface plating before welding or use great care no to breathe the fumes resulting from the welding. Supposed to be really nasty stuff that can kill you? I can hold my breath for up to two minutes and practice this when welding. ;)

Paint, assemble, mount and install!

I'm not sure if this light is DOT approved or not but I can't remember ever being pulled over so they could check for that. On this assembly the upper halogen light acts as the low beam and the BD light is the high beam. There are units that can be wired in to use the BD light for high and low beam available on Amazon for around $15 if you prefer.

20190623_130559.jpg

20190623_141638.jpg

20190623_143915.jpg

  • Like 2
  • Helpful 1

Share this post


Link to post
Share on other sites

Curious to why you went this method instead of HID? Also how did the light output turn out? There are a few of us that have done the HID conversion using a DDM Tuning unit. 

 

 

Share this post


Link to post
Share on other sites
On 7/2/2019 at 7:23 AM, Rider Eh said:

Curious to why you went this method instead of HID? Also how did the light output turn out? There are a few of us that have done the HID conversion using a DDM Tuning unit. 

 

 

I just haven't seen any of those I guess. BD's LEDs are pretty much bulletproof units and the prices are starting to get into a more realistic range these days. Do you have a link for one of the X2 HID retrofits that were done? Now I'm curious what that looks like!

Share this post


Link to post
Share on other sites

 

There is mine and another users. You may find others using the search.

  • Like 1
  • Helpful 1

Share this post


Link to post
Share on other sites

Looks like the light output is pretty comparable to the HID setup. (Image was bench testing the light in the garage with other lights off and doors closed) I wonder about the current draw on the BD LEDs compared to the HID? I wish I had direct way to check lumens output in a scientific manner also. Baja Designs claims the Squadron Sport output is 2260 lumens at 20w current draw. A quick online search shows that most 35W HID put out around 3600 lumen depending on light color, which is definitely more! But the HID does require extra wiring for the Relay and Ballast I think? So I'm still pretty happy with the BD LED. ;) 

I still haven't been out for a night ride with it due to other things going on, but I'll update this when I do!

20190622_183845.jpg

Edited by DirtyErnie

Share this post


Link to post
Share on other sites

Looks pretty good! You don't need a relay for the HID if your handlebar switch is rated for more than 3 amps. You can just wire into the ballast like you would a regular light.

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Reply with:


×